I have AppleCare. It was supposed to be a replacement and then Apple changed it into a repair.
I was also surprised in the return shipping box. The package they used didn’t even fit the AirPods and wouldn’t properly close.
I am having a similar experience. I have the original AirPods Pro from when they first came out. I bought Applecare+ for them. I had the sound issue with the right one last year. I chatted with Apple online at that time and they put a hold on my credit card and shipped me a replacement right AirPods Pro. The replacement right AirPods Pro has been working great since and I promptly sent back the bad one and the credit card hold was released. I was not without the use of my AirPods at all.
Fast forward to this week. Monday I chatted in with Apple Support because the same sound issue has been happening with my LEFT AirPods Pro now. I gave them my Applecare+ Agreement number. Said I have the Crackling/Static sound in Transparency or Noise Cancelling mode when I'm walking around and talking on a phone call.
This time they mailed me an empty box to send back both AirPods Pro inside of the battery base (sans the ear tips). They had to be shipped to Pennsylvania to the repair center to "confirm the sound issue". A short while ago I got an email saying the Apple Technician "couldn't duplicate issue" and the "Original product shipped" back to me.
So, I bought Applecare+, my LEFT AirPods Pro definitely has the known sounds issue, I had to ship off my APPs to be without them for a few days, and the bad one didn't get replaced or repaired but it does have the problem!! ?
So frustrating! Apparently my Applecare+ Agreement means nothing in this situation?
I'm guessing my next step will be to wait until I am traveling near a large city with an Apple Store and see if I can have them check it out and hopefully give me a replacement at a store?? ?♂️